Conveyor plate with integrated roller

ABSTRACT

A conveyor support plate includes an upper transport surface configured to receive objects arranged for travel on a conveyor system and a lower surface arranged opposite the upper transport surface. A pair of transversely extending walls and a pair of side walls connect the upper transport surface and the lower surface. A plurality of cavities are formed in the lower surface between the pair of transversely extending walls and the pair of side walls that terminate below the upper transport surface. The cavities are configured to receive a roller that extends through the lower surface to support the support plate during travel on the convey system.

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims priority to and is a divisional application ofU.S. application Ser. No. 11/290,104, filed Nov. 30, 2005, issued asU.S. Pat. No. 7,556,142 on Jul. 7, 2009, which is hereby incorporated byreference as if fully set forth herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention is directed to a conveyer, and more particularly,to a support plate for a conveyor having integrated rollers to promotetravel along a desired path by reducing torsional, load bearing, andresistive forces on the conveyor.

Conveyors are subjected to many forces when transporting products alonga path. Helical conveyor systems, for example, are common in a widevariety of industries as they provide an efficient means through whichto move products, parts, and the like over vertical distances. However,when traversing a spiraled path between vertical distances, thesehelical conveyer systems are subjected to a variety of forces. Forexample, during operation, these systems are subjected to torsionalforces caused by following the spiraled path, vertical loading forcescaused by following a vertically ascending or descending path, andhorizontal loading forces caused by following the horizontal componentof the path. These forces can be further compounded when carryingsignificant loads and especially when encountering a build-up of debrisalong the spiraled path. Over time, these forces can cause significantwear on the helical conveyor system and/or interfere with the operationof the conveyor system.

In an effort to reduce the stresses associated with these forces,various bearing designs have been utilized. For example, some helicalconveyor systems employ a base chain arranged on the spiraled path thatincludes bearings mounted thereon to create an interface between thebase chain and the spiraled path. In some cases, these bearings may beroller bearings mounted on the base chain to engage the spiraled pathand reduce frictional forces between the base chain and the spiraledpath. While these bearing systems mounted to the base chain can reducesome torsional, vertical, and horizontal forces, the base chain formsbut a small portion of the overall helical conveyor system and, thus,significant forces are still applied to the overall helical conveyorsystem. Accordingly, significant power is required to overcome theseforces and move the helical conveyor along the spiraled path andsignificant wear is incurred over time.

Therefore, it would be desirable to have a system to further reducetorsional, frictional, and loading forces on a conveyor system travelingalong a path.

BRIEF SUMMARY OF THE INVENTION

The present invention overcomes the aforementioned drawbacks byproviding a support plate for a helical conveyor system including aplurality of integrated roller bearings. In particular, a plurality ofcavities is formed in each support plate in which rollers may bedisposed that extend below the support plate and rotate against a guidepath of a spiraled path over which the helical conveyor travels.

In accordance with one aspect of the invention, a conveyor support plateincludes an upper surface configured to receive objects arranged fortravel on a conveyor system and a lower surface arranged opposite theupper surface. The conveyor support plate also includes a leading walland a trailing wall as well as a pair of side walls connecting the uppersurface and the lower surface. A plurality of cavities are formed in thelower surface that terminate below the upper surface and are arrangedbetween the leading and trailing walls and the pair of side walls.Additionally, the plurality of cavities is designed to receive a rollertherein that extends through the lower surface to support the supportplate during travel of the convey system.

In accordance with another aspect of the invention, a conveyor systemincludes a travel path having a horizontally oriented guide surface. Aplurality of support plates are included that have at least two cavitiesextending below a top surface and through a bottom surface. At least oneroller is supported in each of the cavities to rotatably engage thehorizontally oriented guide surface. Accordingly, the rollers supportthe support plates above the horizontally oriented guide surface asconveyor system traverses the travel path.

In accordance with yet another aspect of the invention, a conveyorsystem is designed to travel along a spiral path. The conveyor systemincludes a base chain having pairs of sidebars pivotally connected bycorresponding pins. A plurality of support plates is engaged with thebase chain that have an upper transport surface and a lower surfaceextending along the spiral path. At least one cavity is formed in theplurality of support plates that extends through the lower surface butterminates prior to the transport surface. The conveyor system alsoincludes at least one roller engaged within the each cavity to rollagainst a guide surface of the spiral path as the conveyor systemprogresses over the spiral path.

The foregoing and other features and advantages of the invention will bemade apparent from the following description. In the description,reference is made to the accompanying drawings which form a part hereof,and in which there is shown by way of illustration an embodiment of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a spiral path forming guide surfaces for ahelical conveyor system of the present invention;

FIG. 2 is a bottom perspective view of a helical conveyor system inaccordance with the present invention;

FIG. 3 is a top perspective view of the helical conveyor system of FIG.2;

FIG. 4 is a bottom perspective view of a single support plate andlinking of base chain of the helical conveyor system of FIGS. 2 and 3;

FIG. 5 is a partial bottom exploded perspective view of the singlesupport plate of FIG. 4 showing a fastening system for the rollerbearings;

FIG. 6 is a partial bottom perspective view of a support plate showingan alternative fastening system for the roller bearings in accordancewith the present invention;

FIG. 7 is a partial bottom perspective view of the support plate of FIG.6 showing engaged and disengaged roller bearings;

FIG. 8 is a cross-sectional view of the assembled support plate of FIG.4 along lines 8-8, shown engaged with guide surfaces of the spiral pathof FIG. 1;

FIG. 9 is a plan view of a modular link conveyor system in accordancewith the present invention; and

FIG. 10 is a side elevational view of the modular link conveyor systemof FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a spiral path 10 is shown that presents guidesurfaces for a helical conveyor system of the present invention. Thatis, as will be described, the helical conveyor system of the presentinvention is configured to traverse the spiral path 10 in either anascending or descending direction.

Referring now to FIG. 2, a helical conveyor system 12 includes a basechain 14, such as the roller chain shown, having paired sidebars 16pivotally connected through a plurality of pins 18. Extendingtransversely from one of the pair of sidebars 16 is a pair of arms 20.Extending between the pair of arms 20 and fixed therein by a pin 22 is abearing in the form of a roller 24. In this regard, the roller bearing24 is configured to be supported by the pair of arms 20 and rotate aboutan axis extending along the pin 22.

Engaged with the base chain 14 through an interface 26 is a plurality ofsupport plates 28. Each support plate 28 extends transversely in eitherdirection away from the interface 26 and include a lower surface 34 andan upper transport surface 36 joined by a leading edge 35, a trailingedge 37, and a pair of side walls 39. A plurality of downwardly openingpassages or cavities 30 are formed within the lower surface 34 of eachsupport plate 28. Disposed within each of the cavities 30 is a supportbearing in the form of a roller 32.

As shown in FIG. 2, the cavities 30 extend through the lower surface 34of each support plate such that the rollers 32 extend below the lowersurface 34 of each support plate 28. However, as shown in FIG. 3, thecavities 30 do not extend above an upper transport surface 36 of thesupport plates 28. Therefore, referring to FIGS. 2 and 3, the cavities30 are formed in the plurality of support plates 28 such that theyextend through the lower surface 34 of the support plates 28 butterminate prior to extending to the upper transport surface 36 of thesupport plates 28. As will be described, this configuration enables thehelical conveyer system 12 to move with reduced friction when traversinga spiral path such as shown in FIG. 1, but will not interfere withobjects being transported on the upper transport surface 36 of theplurality of support plates 28.

Additionally, as shown in FIG. 3, it is contemplated that the uppertransport surface 36 may include a variety of features thatadvantageously facilitate both transport of objects disposed on theupper transport surface 36 and movement of the helical conveyor 12 alonga spiral path. For example, substances that increase the coefficientfriction of the upper transport surface 36, such as rubber 38, may bedisposed in a variety of patterns to aid in fixing objects positioned onthe upper transport surface 36 in a given position. Furthermore, aplurality of interlocking ribs 40 may be positioned on the uppertransport surface 36 or, more specifically, form an upper surface of theupper transport surface 36 to provide a more uniform and substantialupper transport surface 36 while simultaneously allowing the flexing ofadjacent support plates 28 necessary to traverse a spiral path, such asshown in FIG. 1. That is, the reciprocally contoured design of the ribs40 as disposed on the support plates 28 forms a more substantial uppertransport surface 36 as well as permits the support plates 28 to flex asthe base chain 14 is curved around a spiral path.

Referring now to FIG. 4, a single support plate 28 is shown engaged witha portion of the base chain 14. As shown, the interface 26 between thesupport plate 28 and base chain 14 is formed as a snap-on connectionconfigured to engage the pins 18 joining the sidebars 16 of the basechain 14. In this regard, an individual support plate 28 may be quicklyand easily removed from engagement with the base chain 14 formaintenance or replacement.

Additionally, in the embodiment shown in FIG. 4, the plurality ofrollers 32 are retained within the respective cavities 30 by way of apin or axle 42 extending through a transverse passage 44 formed withinthe support plate between the upper transport surface 36 and the lowersurface 34. More particularly, the pin 42 is disposed in thetransversely extending passage 44, which extends between the pair ofside walls 39 joining the upper transport surface 36 and the lowersurface 34. Therefore, the pin 42 extends parallel to the transverselyextending leading edge 35 and trailing edge 37 that also join the uppertransport surface 36 and the lower surface 34.

In particular, referring to FIG. 5, as the pin 42 is passed through thetransversely formed passage 44, it extends through each of the cavities30 formed in the support plates 28. Accordingly, each of the rollers 32includes an opening 46 formed therein that, when disposed within acavity 30, aligns coaxially with the transversely extending passage 44such that the pin 42 can be extended through the transversely extendingpassage 44 and pass through each of the openings 46 formed within therollers 32. Therefore, the rollers 32 are rotatably secured within thecavities 30.

Furthermore, a locking mechanism 48 may be utilized that includes a plugor tab 50 configured to engage a recess 52 formed in the support plate28. That is, once the pin 42 is extended through the transverselyextending passages 44 and each respective opening 46 of the plurality ofrollers 32, the locking mechanism 48 may be positioned within the end ofthe transversely extending passage 44 such that the tab 50 engages therecess 52 of the support plate 28 to lock the pin 42 within thetransversely extending passage 44. Alternatively, it is contemplatedthat the locking mechanism 48 may be integrally formed on an end 54 ofthe pin 42.

Referring now to the embodiment shown in FIGS. 6 and 7, the supportplate 28 includes an alternative system for securing the rollers 32within the cavities 30. Specifically, as best shown in FIG. 7, thesupport plate 28 may include a pair of locking clips 56 integrallyformed within each cavity 30. Accordingly, these clips or snap fittings56 are configured to engage a set of pins 58 integrally formed with theroller 32 and extending therefrom on either side. In this regard, theroller 32 can be aligned with the cavity 30 and depressed into thepassage whereby the pins 58 slide into the snap fitting 56 and to beengaged therewith. Once the roller is positioned within the cavity 30,the snap fittings 56 permit the roller to rotate about an axis 60extending along the pins 58 while retaining the rollers 32 within thecavity 30.

Referring now to FIG. 8, a cross-sectional view taken along lines 8-8 ofFIG. 4 is shown with the support plate 28 and base chain 14 (e.g.,roller chain) engaged with the spiral path 10 of FIG. 1. As shown, thespiral path 10 includes a recess 62 within which the base chain 14 andassociated components are disposed. Accordingly, the spiral path 10includes a first guide surface 64 that is engaged by the rollers 32 anda second guide surface 66 engaged by the roller bearing 24 supported bythe pair of arms 20 extending from the sidebar 16 of the base chain 14.As the helical conveyor system 12 traverses over the spiral path 10, thesupport plate 28 is supported on the rollers 32 against the first,horizontally-oriented, guide surface 64. In this regard, the majority ofthe weight of objects positioned on the helical conveyor system 12 issupported by the rollers 32 through the support plates 28. Accordingly,loading forces associated with the objects positioned on the uppertransport surface 36 and frictional forces associated with traversingthe spiral path 10 are significantly reduced by the rollers 32 rollingover the first guide surface 64 of the spiral path 10.

To further reduce torsional and frictional forces associated withtraversing the spiral path 10, the bearing roller 24 is configured toroll along the second, vertically-oriented, guide surface 66 of thespiral path 10. Additionally, in an effort to resist vertical andhorizontal forces that would promote disengaging the helical conveyorsystem 12 from the spiral path 10, the bearing roller 24 may have acontoured surface such as a lip 68 formed thereon and configured to bereceived by a reciprocally contoured surface 70 formed in the secondbearing surface 66. Though a rotational axis 72 of the bearing roller 24is shown as being substantially vertical, it is contemplated that therotational axis 72 may be angled to further facilitate engagement withthe reciprocally contoured second guide surface 66. For example, if thebearing roller 24 includes a less dramatic contour than the lip 68 shownin FIG. 8, such as an acutely angled depression, it may be desirable toadjust the axis of rotation from the vertical position shown in FIG. 8to more securely engage the bearing roller 24 with the second guidesurface 66.

Accordingly, through the rollers 32 formed in the support plates 28 aswell as the contoured roller bearing 24 extending from the base chain14, torsional, loading, and frictional forces are significantly reduced,thereby, reducing the amount of power required to traverse the helicalconveyor system 12 over the spiral path 10. Likewise, wear andsusceptibility to debris positioned on the spiral path 10 issignificantly reduced. Accordingly, maintenance and upkeep costsassociated with operating the helical conveyor system 12 are alsoreduced.

It is also contemplated that the cavities 30 and roller 32configurations may be utilized with a modular belt. For example,referring now to FIGS. 9 and 10, a modular link belt 74 designed tofollow a straight path is shown that incorporates the roller system ofthe present invention. Of course, the modular belt can be designed tofollow a curved path without departing from the scope of the invention.In particular, the modular belt 74 also includes a plurality of supportplates 28, or belt modules. However, rather than being joined through abase chain, the support plates 28 include link ends 76 along the leadingedge 35 configured to engage reciprocally arranged link ends 76 disposedalong the trailing edge 37 of an adjacent support plate 28. A pin 78 isthen passed through coaxially aligned passages formed through the linkends 76 to secure together adjacent support plates 28.

Again, as described above, the support plates 28 include the lowersurface 34 and the upper transport surface 36 joined by the leading edge35, trailing edge 37, and pair of side walls 39. In this regard, theplurality of downwardly opening passages or cavities 30 are again formedwithin the lower surface 34 of each support plate 28 to house a roller32. As shown in FIGS. 9 and 10, the pin 42 may be used to secure therollers 32 within each cavity 30. However, as described with respect toFIGS. 6 and 7, clips or other similar retaining systems may be utilizedinstead of the pin 42.

As shown in FIG. 10, it is contemplated that additional rollers 80, 82may be disposed within the links 76 arranged along the leading edge 35and the trailing edge 37, respectively. Accordingly, three separate setsof rollers 32, 80, 82 can be formed on each support plate 28. However,as shown, none of the rollers 32, 80, 82 extend through the uppertransport surface 36.

Therefore, a conveyor system is created that significantly reducestorsional, loading, and frictional forces experienced as the conveyorbelt traverses a given path. As such, the amount of power required tooperate the conveyor system is reduced. Similarly, wear andsusceptibility to debris positioned encountered during operation of theconveyor system is significantly reduced. Accordingly, maintenance andupkeep costs associated with operating the conveyor system are alsoreduced.

While there have been shown and described what is at present consideredthe preferred embodiments of the invention, it will be obvious to thoseskilled in the art that various changes and modifications can be madetherein without departing from the scope of the invention defined by theappended claims.

1. A conveyor system comprising: a travel path having a guide surface; and at least one conveyor support plate, comprising: an upper transport surface; a lower surface arranged opposite the upper transport surface; at least one wall connecting the upper transport surface and the lower surface; at least one cavity formed in the lower surface and terminating prior to the upper transport surface; and at least one roller engaged within the at least one cavity and extending through the lower surface to support the conveyor support plate during travel of the conveyor support plate; wherein the at least one roller rotatably engages the guide surface and supports the at least one conveyor support plate above the guide surface as the at least one conveyor support plate traverses the travel path.
 2. The conveyor system of claim 1 further comprising a snap fitting disposed within the at least one cavity configured to rotatably secure the at least one roller in the at least one cavity.
 3. The conveyor system of claim 1 further comprising a transverse passage extending coaxially through the at least one cavity and a pin extending through the transverse passage and an opening formed in the at least one roller to secure the at least one roller in the at least one cavity.
 4. The conveyor system of claim 1 wherein the upper transport surface is configured to support objects positioned on the at least one conveyer support plate.
 5. The conveyor system of claim 1 wherein a plurality of the at least one conveyor support plates form an endless conveyor belt.
 6. The conveyor system of claim 1 further comprising: a base chain extending along the travel path and engaged with the at least one conveyor support plate near a center of the lower surface; and wherein the at least one cavity includes two cavities that are arranged on opposing sides of the base chain.
 7. The conveyor system of claim 6 further comprising: at least one pair of arms extending from the base chain; at least one bearing roller supported by each pair of arms to engage a vertically oriented and contoured guide surface of the travel path; and wherein the at least one bearing roller is configured to restrain the at least one conveyor support plate from disengaging the travel path through an interface of the at least one bearing roller with the contoured guide surface.
 8. A conveyor support plate comprising: an upper transport surface; a lower surface arranged opposite the upper transport surface; at least one wall connecting the upper transport surface and the lower surface; at least one cavity formed in the lower surface and terminating prior to the upper transport surface; and at least one roller engaged within the at least one cavity and extending through the lower surface to support the conveyor support plate during travel of the conveyor support plate.
 9. The conveyor support plate of claim 8 further comprising an axle passage extending between the upper transport surface and the lower surface, and through the at least one cavity to receive an axle extending through the at least one cavity and a coaxially aligned passage formed in the at least one roller to rotatably secure the at least one roller in the at least one cavity.
 10. The conveyor support plate of claim 8 further comprising a snap fitting disposed within the at least one cavity to rotatably secure the at least one roller therein.
 11. The conveyor support plate of claim 8 further comprising an interface arranged on the lower surface configured to engage a base chain joining adjacent conveyor support plates in a helical conveyor system.
 12. The conveyor support plate of claim 8 further comprising a plurality of links extending from the at least one wall to engage a reciprocally arranged plurality of links extending from an adjacent conveyor support plate.
 13. The conveyor support plate of claim 12 further comprising a pin configured to extend through passages formed in each of the plurality of links to secure together the adjacent conveyor support plates to form a modular belt conveyor. 